CEMGUARD® Fly Ash

Brand/ Product

CEMGUARD® Fly Ash
(Pulverized Fuel Ash)

Standard

ASTM C618 Class-F
BS EN 450 Category N / S
BS 3892, IS 3812
GB/T 1596-2005
CE Marking*

Supply Capacity

Export: 480,000 TPA
Local: 240,000 TPA

Packing

Big Bags, Small Bags, Bulk

Shipment

Containerized
Break-Bulk
Bulk (Road and Sea)

Ships In

Export: 12-15 days
Local: 2-4 days
More
  We ship globally with competitive prices and flexible payment options

Technical Documents
  •   Technical Data Sheet
  •   Material Safety Data Sheet
  •   Certificate of Analysis

CEMGUARD® Fly Ash is a pozzolanic material, captured in electro-static precipitators as a by-product from coal-fired thermal power stations. It consists of small, hard and spherical particles rich in silica (glass) and alumina, with pozzolanic properties. It complements Portland cement upon hydration by reacting with free lime (calcium hydroxide) to form an additional durable binder, namely calcium silicate hydrate. The spherical particles also have a ‘ball-bearing’ effect, which allows concrete to be produced using less water.

CEMGUARD® Fly Ash is subject to processing/ quality control to regulate its fineness (particle size and distribution, shape and glass content) and unburnt carbon (loss-on-ignition), thus giving quality-assured material which is consistent, predictable and suitable for varied applications. We are working towards CE Marking for CEMGUARD® Fly Ash.

CEMGUARD® Fly Ash is mainly used as a partial replacement of cement in concrete, and has unique properties that benefit both fresh and hardened concrete. Its key advantages include reduced heat of hydration, improved workability, enhanced durability and longer setting time. It can be effectively used where aggregates have poor grading and shape, resulting in bleeding and segregation. It is also suited for mass concrete applications, and in hot and aggressive environments where early-age thermal cracking and durability are major concerns. General replacement of cement with CEMGUARD® Fly Ash in concrete can be 15-35% by weight for normal structures. However, for special structures such as dams, the replacement levels can increase up to 70%. The service life of structures using CEMGUARD® Fly Ash is enhanced by more than 100% on account of superior durability of concrete. Fly Ash use in concrete qualifies for credit under the U.S. Green Building Council's popular LEED® rating system for sustainable construction.

Applications of CEMGUARD® Fly Ash encompass structural and ready mix concrete, cement, plastering and brick mortar, pre-cast and pre-stressed concrete, pumped concrete, bricks and blocks. CEMGUARD® Fly Ash can either be pre-blended with the cement or sold separately for subsequent blending at the concrete batching plant. It is recommended that the volume of water may be reduced by 2.5% and quantity of sand may be reduced by 0.5% for every 10% of CEMGUARD® Fly Ash used instead of cement in concrete. Apart from the use of CEMGUARD® Fly Ash in blended cements or as a direct addition in concrete manufacture, CEMGUARD® Fly Ash may also be used as a raw material ingredient in clinker production where the silica and alumina contents are of particular interest. Non cementitious uses for CEMGUARD® Fly Ash are wide ranging and include use in roads, asphalt, soil and waste stabilisation, lightweight aggregates, etc. It can also be used to replace the filler ingredient of asphalt mix, which is usually 7-10%, leading to reduction in bitumen consumption by 10-15% resulting in a superior asphalt mix and cost-savings.

See Map with our Operations Across India

BIG BAGS

  • Net Weight: 1.4 Metric Tons
  • High quality, UV resistant PP fabric with lamination and heavy duty inner liner for moisture resistance and extended shelf life
  • Swan neck with double layer protection to eliminate ingress of moisture/ water and foreign elements
  • Tamper-resistant packing
  • Economical to transport over long distances and can be easily stored in warehouses
  • Most popular packing option for containerized and break-bulk export
  • Option of shrink wrapping at a nominal cost
  • Typical dimensions of big bag: 90x90x135 cm
  • Typical pallet dimensions: 99x99 cm

SMALL BAGS

  • Net Weight: 25 KG / 40 KG
  • High quality, UV resistant PP fabric with lamination for moisture resistance and extended shelf life
  • Tamper-resistant packing
  • Convenient manual handling and mixing on site
  • Can be easily stored in smaller warehouses and sites
  • Economical to transport over long distances
  • Can be containerized for exports
  • Option of shrink wrapping at a nominal cost

BULK (ROAD)

  • Best suited for ready mix concrete plants and large projects with regular consumption
  • Direct delivery to site and discharge into silos, with no double handling
  • Tamper-resistant delivery, therefore no adulteration possible
  • No loss of material and wastage during handling
  • Scheduled delivery, no need to stock inventory
  • Helps optimize working capital

BULK (SEA)

  • Shipping in specialized bulk vessels
  • Eliminates big bagging and de-bagging operations
  • Increases supply chain efficiency
  • Avoids double handling and reduces end-to-end logistics costs as well as operational costs
  • More environment-friendly
  • Requires storage, loading and discharge infrastructure on both sides

There are so many Fly Ash suppliers in the market!

The large generation of Fly Ash in India has given birth to plenty of unorganized traders and exporters, who have no product knowledge nor any understanding of the business. Such fly-by-night operators often rely on malpractices to misguide customers and sell substandard quality Fly Ash at cheap, below-market prices to make a quick buck. Recently, some rogue traders have started supplying highly coarse Fly Ash (retention over 45 micron > 34%) with a thin layer of fine Fly Ash on top of the big bag to cheat customers. A few others are also supplying dried Pond Ash available for free in the name of Fly Ash. Such rogue traders send good quality Fly Ash samples for testing/ approval, and then ship substandard material packed in poor quality bags (sometimes even without liners), without any quality control. They have no infrastructure and no resources. When something goes wrong, they simply run away!

Beware, a lower price always comes with compromises and risks. Procuring such cheap Fly Ash could have disastrous effects on concrete and significant construction hazards, perhaps leading to death of people in case the concrete structure collapses! An apparent short-term gain due to lower prices could get wiped out by much bigger losses and long-term damage to the reputation and business of the buyer.

Please check the following before procuring Fly Ash from any supplier:

  • 'Valid' long-term supply contract with the power station
  • Infrastructure, quality control, bagging systems and warehousing/ logistics set up
  • ‘Valid’ rental agreement of the claimed infrastructure and warehousing facility
  • Quality control process
  • Multiple, periodic independent lab test reports for the last 6 months (preferably from SGS)
  • Detailed bag specifications to see GSM of fabric, weight of bag, liner, lamination, etc.
  • Verifiable sales volumes in past 12 months as proof of regular supplies in local and export markets, backed by genuine customer references
  • Company documents to verify credibility and experience in the business (more the better!)

If you have unknowingly bought cheap Fly Ash, please test samples from the top, middle and bottom of big bags for full compliance to standards before usage. If found out of spec, kindly blacklist the supplier and do not use the Fly Ash in concrete for safety reasons.

CEMGUARD® Fly Ash is competitively priced but not cheap. Proudly!

De-Bagging of Fly Ash

The discharge of big bags into bulk tankers or batching plants is very often problematic, due to lumps created by fine particles due to vibration, ambient humidity, temperature fluctuations and compaction during shipping, transportation and storage. JAYCEE recommends a simple but effective de-bagging facility to remove lumps, and load bulk tankers/ silos in a dust-free manner. The debagging equipment is furnished with an in-built lump breaker macerating any material containing lumps again into free flowing powder. Two operators are required to man the system and one forklift or Hydra is required to carry the big bags to the lift-up point of the de-bagging station. All large customers and distributors in every territory should install a de-bagging station with in-built lump breaker to have seamless discharge of big bags. JAYCEE can also provide such systems in cases where it is not available locally.

Classification of Fly Ash

Old coal-fired thermal power stations are not able to pulverize coal effectively and do not have efficient combustion as in modern power stations with advance technologies. Thus, the Fly Ash generated from old power stations is coarse and inconsistent, often with high LOI necessitating additional classification to control fineness and LOI before it can be utilized effectively in concrete and other applications. Modern power stations have advance technologies for effective pulverization and efficient combustion of coal, with integrated electro-static precipitators with multiple fields for segregating and capturing Fly Ash. As a consequence, the Fly Ash generated from modern power stations has low LOI and high consistency in fineness (varying grades), requiring no further classification in most cases.

Colour of Fly Ash

The colour of Fly Ash can vary from tan and light colour to brownish, grey and dark grey colour, depending on the coal source. While one must ensure that physical and chemical specifications of Fly Ash fully comply with the required international standards, it is a misconception that colour of Fly Ash has an effect on its performance in concrete and other applications. The performance of Fly Ash is independent of colour per se, but depends on various other parameters like fineness, LOI, chemical composition, etc.

Environmental Impact of Fly Ash

Every single ton of Fly Ash used reduces demand and production of Ordinary Portland Cement by one ton, resulting in massive energy savings and conservation of natural resources. Every ton of Portland cement produced even with the best technologies creates 0.9 tons of CO2 emissions, which is one of the main contributors to the Greenhouse effect.

The service life of structures using Fly Ash is enhanced by more than 100% on account of superior durability of concrete. Since the structure will last longer, no additional raw materials and energy will be required to rebuild or repair it, which is a significant ecological advantage. Fly Ash use in concrete qualifies for credit under the U.S. Green Building Council's popular LEED® rating system for sustainable construction.

CEMGUARD® FBA (Furnace Bottom Ash)

Furnace Bottom Ash is the "coarse" ash fraction produced by coal-fired power stations when pulverised fuel is burned at high temperatures and pressures. It has similar chemical properties to Fly Ash, consisting predominantly of oxides of silica, aluminium and iron, but has a sand-like gritty texture. The actual physical properties of FBA are, to a large extent, governed by the type of furnaces used and whether the FBA is quenched in water or is cooled in a dry bottom grate such as the Megaldi system. With regards to key market applications, FBA is primarily used as a lightweight aggregate in the manufacture of building blocks and other such products for the construction industry.

It can also be used in:

  • Foamed concrete as a trench fill
  • Structural lightweight fill material, such as in embankments on soft or poor ground conditions
  • Raw feed for cement kilns
  • Equestrian arenas
  • Drainage materials - FBA is also popular as a free draining base and growing media in the fairways and greens of golf courses.

CEMGUARD® PA (Pond Ash)

Pond Ash (Conditioned Ash) is ash which has been slurried at the power station and pumped to lagoons (ash-ponds). This material is excavated from lagoons and allowed to stabilise to reduce its water content. If desired, it can also be screened prior to dispatch. Pond Ash is easily handled in tipper trucks and the addition of water makes it easy to compact. Being a low density material, it can be used as a fill material over weak or soft ground. When used in grouts for fill applications, it gives good yields whilst the continuing reaction between Fly Ash and free lime from cement means that it offers strength gains with time. Conditioned ash is self-supporting, minimising the need for shoring. It has low permeability, assisting water run-off and it is a stable material - both chemically and physically. The spherical shape of the ash particles provides the additional benefits of a reduced water to solids ratio, reduced bleeding and good flow properties.

Some cement producers also replace 2-3% of Clinker with Pond Ash (with moisture content < 10%), in addition to usage of Dry Fly Ash. This results in incremental increase in cement performance and more importantly, cost optimization along with significant environmental benefits over the long term.

Typical uses include:

  • General or structural fill material
  • Road bases for highway construction
  • Capping material on landfill sites
  • Waste stabilisation
  • Aggregate/filler in cementitious grouts, or bituminous road materials
  • Raw material feed in cement manufacture

Ternary Blends

Triple (ternary) blend concrete made with CEMENT + CEMGUARD® Fly Ash + CEMGUARD® Microsilica has very high performance. The chemical binding of chlorides by Fly Ash (due to its alumina content) works together with the reduced permeability due to Microsilica to protect steel from corrosion and significantly enhance the durability of concrete. Key advantages of triple blend concrete are reduced sensitivity of concrete to effects of insufficient curing, very low chloride permeability, high compressive strength, superior durability and lower life-cycle costs.

Supply Chain

Supply Chain

Robust, efficient supply chain with world-class, all-season infrastructure to handle large volumes

Technical Expertise

Technical Expertise

Technical Support and Solutions from Industry Experts

Quality Control

Quality Control

Stringent quality control processes, online monitoring, full compliance to IS, ASTM, BS-EN standards, ISO 9001, CE Marking*

Packing Options

Packing Options

Multiple packing options including big bags, small bags, break-bulk and bulk (road and sea)

Logistics

Logistics

Strong expertise in containerized, break-bulk and bulk shipments

Commercial Terms

Commercial Terms

Competitive prices and flexible payment options

Service

Service

Super-responsive service and communication, seamless collaboration through technology

Values and Experience

Values and Experience

Trust, ethics and transparency, proven track record since 1986